A comprehensive experimental investigation of the wear behaviour of coated spur polymer gears made of POM is performed in this study. Three different thicknesses of aluminium (Al) coatings were investigated and deposited by the Physical Vapour Deposition (PVD) process. The Al coating was deposited in three steps: By plasma activation, metallisation of the aluminium by the magnetron sputtering process, and plasma polymerisation. The wear of the gears was tested on an in-house developed testing rig for different torques (16, 20, and 24 Nm) and a rotational speed of 1000 rpm. The duration of the experiments was set to 13 h, when the tooth thickness and, consequently, the wear of the tooth flank were recorded. The experimental results showed that the influence of metallisation with aluminium surface coatings on the wear behaviour of the analysed polymer gear is not significantly important. The results also showed that the gears with a thicker aluminium coating showed greater wear than gears with a thinner coating or even without a coating. This is probably due to the fact that the aluminium particles that started to deviate during gear operation represented the abrasive material, which led to the faster wear of the contacting surfaces of the meshing gear flanks.
Keywords: aluminium PVD coating; multilayer coating; polymer gears; wear.